Page 329 of 2248

B3M0083A
3) Install drive pinion collar5, needle bearing6(25x30
x 20), adjusting washer No. 2
7(25 x 36 x 4), thrust bear-
ing
8(25 x 37.5 x 3), adjusting washer No. 19(25x36
x t) and differential bevel gear sleeve
10in that order.
NOTE:
Be careful because spacer must be installed in proper
direction.
A: Driven shaft
B: Driven pinion shaft
B3M0084A
G3M0625
4. ADJUSTMENT OF THRUST BEARING PRELOAD
1) After completing the preceding steps 1) through 3),
select adjusting washer No. 2 so that dimension
His zero
through visual check. Position washer (18.3 x 30 x 4) and
lock washer (18 x 30 x 2) and install lock nut (18 x 13.5).
G3M0626
2) Using ST1, ST2 and ST3, tighten lock nut to the speci-
fied torque.
ST1 899884100 HOLDER
ST2 498427100 STOPPER
ST3 899988608 SOCKET WRENCH (27)
Tightening torque:
118±8 N⋅m (12±0.8 kg-m, 86.8±5.8 ft-lb)
B3M0085A
3) After removing ST2, measure starting torque using
torque driver.
ST1 899884100 HOLDER
ST3 899988608 SOCKET WRENCH (27)
Starting torque:
54±25 N⋅m (5.5±2.5 kg-m, 40±18 ft-lb)
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3-1SERVICE PROCEDURE
5. Drive Pinion Assembly (AWD Model)
Page 330 of 2248

G3M0606
4) If starting torque is not within specified limit, select new
adjusting washer No. 1
2and recheck starting torque.
Adjusting washer No. 1
Part No. Thickness mm (in)
803025051 3.925 (0.1545)
803025052 3.950 (0.1555)
803025053 3.975 (0.1565)
803025054 4.000 (0.1575)
803025055 4.025 (0.1585)
803025056 4.050 (0.1594)
803025057 4.075 (0.1604)
G3M0606
5) If specified starting torque range cannot be obtained
when a No. 1
2adjusting washer is used, then select a
suitable No. 2
3adjusting washer from those listed in the
following table. Repeat steps 1) through 4) to adjust start-
ing torque.
Starting torque Dimension H Washer No. 2
Low Small Select thicker one.
High Large Select thinner one.
Adjusting washer No. 2
Part No. Thickness mm (in)
803025059 3.850 (0.1516)
803025054 4.000 (0.1575)
803025058 4.150 (0.1634)
6) Recheck that starting torque is within specified range,
then clinch lock nut at four positions.
55
3-1SERVICE PROCEDURE
5. Drive Pinion Assembly (AWD Model)
Page 331 of 2248

G3M0628
6. Drive Pinion Assembly (FWD Model)
A: DISASSEMBLY
1) Loosen lock nut using ST1 and ST2.
ST1 499987100 or 499987003 or 899984103 SOCKET
WRENCH (35)
ST2 899884100 HOLDER
NOTE:
Remove caulking before taking off lock nut.
B3M0341A
2) Remove 5th driven gear using a press.
ST 498077000 5TH DRIVEN GEAR REMOVER
G3M0610
3) Remove woodruff key.
4) Remove roller bearing (29 x 74 x 38) and 3rd-4th driven
gear using ST1 and ST2.
ST1 899714110 REMOVER
ST2 499757002 SNAP RING PRESS
G3M0611
5) Remove 2nd driven gear assembly.
6) Remove 3rd-4th driven gear key.
7) Remove 1st driven gear, 2nd gear bushing, and gear &
hub assembly using ST1 and ST2.
Replace gear and hub if necessary. Do not attempt to dis-
assemble if at all possible because they must engage at a
specified point. If they have to be disassembled, mark the
engaging point beforehand.
ST1 499757002 SNAP RING PRESS
ST2 899714110 REMOVER
G3M0632
8) Remove 1st gear bushing, 1st driven gear thrust plate,
and roller bearing (41 x 71 x 23) using ST and press.
ST 498517000 REPLACER
CAUTION:
Replace roller bearing (41 x 71 x 23) with a new one if
this disassembly is performed.
56
3-1SERVICE PROCEDURE
6. Drive Pinion Assembly (FWD Model)
Page 332 of 2248
B3M0077A
B: ASSEMBLY
1) Assemble gear and hub assembly.
A: 1st gear side
B: 2nd gear side
C: Flush surface
D: Stepped surface
NOTE:
Use new gear and hub assembly, if gear or hub have
been replaced.
Position open ends of springs 120°apart.
G3M0634
2) Assemble sleeve and hub assembly.
NOTE:
Make sure bent sections of springs on both sides are kept
180°apart and hooked at hub’s holes.
G3M0635
3) Drive roller bearing onto drive pinion shaft and 1st
driven gear thrust washer
1using ST1 and ST2.
ST1 499877000 INSTALLER
ST2 499277100 INSTALLER
CAUTION:
Use new roller bearing, 1st gear thrust washer.
G3M0636
4) Install 1st-2nd driven gear bushing1onto drive pinion
shaft.
NOTE:
Bushing may be installed with either side up.
ST1 499877000 INSTALLER
ST2 499277100 INSTALLER
57
3-1SERVICE PROCEDURE
6. Drive Pinion Assembly (FWD Model)
Page 333 of 2248
5) Measure outside diameter of 1st driven gear bushing to
determine suitable 1st driven gear.
Bushing outside diameter
mm (in)1st driven gear
41.983—41.996
(1.6529—1.6534)32231AA320
41.968—41.982
(1.6523—1.6528)32231AA330
41.954—41.967
(1.6517—1.6522)32231AA340
G3M0637
6) Install 1st driven gear, 1st-2nd balk ring and gear and
hub assembly (already assembled in previous step) to
drive pinion shaft by hand.
NOTE:
Align ring groove with insert.
G3M0638
7) Install 1st-2nd driven gear bushing1to drive pinion
shaft using ST1 and ST2.
ST1 499877000 INSTALLER
ST2 499277100 INSTALLER
G3M0639
8) Install 2nd driven gear1and 1st-2nd balk ring to drive
pinion shaft by hand.
9) Install key into the groove on drive pinion shaft and
install 3rd-4th driven gear.
NOTE:
Ball bearing may be installed without using the tool. There
should be no problem.
ST 499877000 INSTALLER
58
3-1SERVICE PROCEDURE
6. Drive Pinion Assembly (FWD Model)
Page 334 of 2248
G3M0640
10) Install ball bearing (29 x 74 x 38) on drive pinion shaft
with ST.
ST 499277100 INSTALLER
G3M0617
11) Position woodruff key in groove on the rear of drive
pinion shaft. Install 5th driven gear onto drive shaft using
ST and press.
ST 499277100 INSTALLER
CAUTION:
Face 5th driven gear in the correct direction.
Be careful not to dislocate woodruff key while
installing 5th gear.
B3M0353A
G3M0628
12) Install lock washer and tighten lock nut to the specified
torque using ST1 and ST2.
ST1 499987100 or 499987003 or 899984103 SOCKET
WRENCH (35)
ST2 899884100 HOLDER
CAUTION:
Discard old lock nuts, replace with new ones.
Secure lock nut in four places.
Tightening torque:
11 2—124 N⋅m (11.4—12.6 kg-m, 82—91 ft-lb)
59
3-1SERVICE PROCEDURE
6. Drive Pinion Assembly (FWD Model)
Page 335 of 2248

B3M0087A
7. Main Shaft Assembly
A: DISASSEMBLY
1) Put vinyl tape around main shaft splines to protect oil
seal from damage. Then pull out oil seal and needle bear-
ing by hand.
2) Remove lock nut from transmission main shaft assem-
bly.
NOTE:
Remove caulking before taking off lock nut.
ST1 498937000 TRANSMISSION HOLDER
ST2 499987003 SOCKET WRENCH (35)
G3M0644
3) Remove insert stopper plate1, sleeve and hub assem-
bly No. 2, baulk ring
3, 5th drive gear4, and needle
bearing
5(32 x 36 x 25.7).
G3M0645
4) Using ST1, ST2 and a press, remove:
5th needle bearing inner race
1
5th gear thrust washer2
Ball bearing3(25.5 x 65 x 31)
4th gear thrust washer
4
4th drive gear5
Sleeve and hub assembly6
Baulk ring7
4th needle bearing8
4th needle bearing inner race9
3rd drive gear10
ST1 899864100 REMOVER
ST2 899714110 REMOVER
NOTE:
Replace sleeve and hub with new ones. Do not attempt to
disassemble because they must engage at a specified
point. If they should be disassembled, mark engagement
point on splines beforehand.
60
3-1SERVICE PROCEDURE
7. Main Shaft Assembly
Page 336 of 2248
B3M0088A
B: ASSEMBLY
1) Assemble sleeve and hub assembly for 3rd-4th and, 5th
and high-low synchronizing.
NOTE:
Position open ends of spring 120°apart.
A: Two holes for discrimination (3rd-4th hub)
B3M0089A
B: One hole for discrimination (5th hub)
2) Install 3rd drive gear, baulk ring, and sleeve and hub
assembly for 3rd-4th needle bearing (32 x 36 x 25.7) on
transmission main shaft.
NOTE:
Align groove in baulk ring with shifting insert.
G3M0648
3) Install 4th needle bearing race1onto transmission
main shaft using ST1, ST2 and a press.
ST1 899714110 REMOVER
ST2 499877000 RACE 4-5 INSTALLER
B3M0090A
4) Install baulk ring, needle bearing (32 x 30 x 25.7), 4th
drive gear and 4th gear thrust washer to transmission main
shaft.
NOTE:
Face thrust washer in the correct direction.
a: Groove
b: 4th gear side
61
3-1SERVICE PROCEDURE
7. Main Shaft Assembly